7 Del. Admin. Code § 1138-12.0
Current through Register Vol. 28, No. 1, July 1, 2024
Unless defined below, all terms in 12.0 of this regulation have the meanings given them in the Act, or in 3.0 of this regulation.
"Add-on air pollution control device" means equipment installed on a process vent that reduces the quantity of a pollutant that is emitted to the air.
"Afterburner" means an air pollution control device that uses controlled flame combustion to convert combustible materials to noncombustible gases; also known as an incinerator or a thermal oxidizer.
"Aluminum scrap" means fragments of aluminum stock removed during manufacturing (i.e., machining), manufactured aluminum articles or parts rejected or discarded and useful only as material for reprocessing, and waste and discarded material made of aluminum.
"Aluminum scrap shredder" means a unit that crushes, grinds, or breaks aluminum scrap into a more uniform size prior to processing or charging to a scrap dryer/delacquering kiln/decoating kiln, or furnace. A bale breaker is not an aluminum scrap shredder.
"Bag leak" detection system means an instrument that is capable of monitoring particulate matter loadings in the exhaust of a fabric filter (i.e., baghouse) in order to detect bag failures. A bag leak detection system includes, but is not limited to, an instrument that operates on triboelectric, light scattering, light transmittance, or other effect to monitor relative particulate matter loadings.
"Chips" means small, uniformly-sized, unpainted pieces of aluminum scrap, typically below 11/4 inches in any dimension, primarily generated by turning, milling, boring, and machining of aluminum parts.
"Clean charge" means furnace charge materials, including molten aluminum; T-bar; sow; ingot; billet; pig; alloying elements; aluminum scrap known by the owner or operator to be entirely free of paints, coatings, and lubricants; uncoated/unpainted aluminum chips that have been thermally dried or treated by a centrifugal cleaner; aluminum scrap dried at 343°C (650°F) or higher; aluminum scrap delacquered/decoated at 482°C (900°F) or higher, and runaround scrap.
"Cover flux" means salt or salts added to the surface of molten aluminum in a group 1 or group 2 furnace, without agitation of the molten aluminum, for the purpose of preventing oxidation.
"Customer returns" means any aluminum product which is returned by a customer to the aluminum company that originally manufactured the product prior to resale of the product or further distribution in commerce, and which contains no paint or other solid coatings (i.e., lacquers).
"D/F" means dioxins and furans.
"Dioxins and furans" mean tetra-, penta-, hexa-, and octachlorinated dibenzo dioxins and furans.
"Dross" means the slags and skimmings from aluminum melting and refining operations consisting of fluxing agent or agents, impurities, or oxidized and non-oxidized aluminum, from scrap aluminum charged into the furnace.
"Dross-only furnace" means a furnace, typically of rotary barrel design, dedicated to the reclamation of aluminum from dross formed during melting, holding, fluxing, or alloying operations carried out in other process units. Dross and salt flux are the sole feedstocks to this type of furnace.
"Emission unit" means a group 1 furnace or in-line fluxer at a secondary aluminum production facility.
"Fabric filter" means an add-on air pollution control device used to capture particulate matter by filtering gas streams through filter media; also known as a baghouse.
"Feed/charge" means, for a furnace or other process unit that operates in batch mode, the total weight of material (including molten aluminum, T-bar, sow, ingot, etc.) and alloying agents that enter the furnace during an operating cycle. For a furnace or other process unit that operates continuously, feed/charge means the weight of material (including molten aluminum, T-bar, sow, ingot, etc.) and alloying agents that enter the process unit within a specified time period (e.g., a time period equal to the performance test period). The feed/charge for a dross only furnace includes the total weight of dross and solid flux.
"Fluxing" means refining of molten aluminum to improve product quality, achieve product specifications, or reduce material loss, including the addition of solvents to remove impurities (solvent flux); and the injection of gases such as chlorine or chlorine mixtures, to remove magnesium (demagging) or hydrogen bubbles (degassing). Fluxing may be performed in the furnace or outside the furnace by an in-line fluxer.
"Furnace hearth" means the combustion zone of a furnace in which the molten metal is contained.
"Group 1 furnace" means a furnace of any design that melts, holds, or processes aluminum that contains paint, lubricants, coatings, or other foreign materials with or without reactive fluxing, or processes clean charge with reactive fluxing.
"Group 2 furnace" means a furnace of any design that melts, holds, or processes only clean charge and that performs no fluxing or performs fluxing using only nonreactive, non-HAP-containing/non-HAP-generating gases or agents.
"Hazardous air pollutant" or "HAP" means any air pollutant listed in or pursuant to section 112(b) of the Act.
"HCl" means, for the purposes of 12.0 of this regulation, emissions of hydrogen chloride that serve as a surrogate measure of the total emissions of hydrogen chloride, hydrogen fluoride, and chlorine.
"In-line fluxer" means a device exterior to a furnace, located in a transfer line from a furnace, used to refine (flux) molten aluminum; also known as a flux box, degassing box, or demagging box.
"Internal scrap" means all aluminum scrap regardless of the level of contamination which originates from castings or extrusions produced by an aluminum die casting facility, aluminum foundry, or aluminum extrusion facility, and which remains at all times within the control of the company that produced the castings or extrusions.
"Lime" means calcium oxide or other alkaline reagent.
"Lime-injection" means the continuous addition of lime upstream of a fabric filter.
"Melting/holding furnace" means a group 1 furnace that processes only clean charge, performs melting, holding, and fluxing functions, and does not transfer molten aluminum to or from another furnace except for purposes of alloy changes, off-specification product drains, or maintenance activities.
"Operating cycle" means for a batch process, the period beginning when the feed material is first charged to the operation and ending when all feed material charged to the operation has been processed. For a batch melting or holding furnace process, operating cycle means the period including the charging and melting of scrap aluminum and the fluxing, refining, alloying, and tapping of molten aluminum (the period from tap-to-tap).
"PM" means, for the purposes of 12.0 of this regulation, emissions of particulate matter that serve as a measure of total particulate emissions and as a surrogate for metal HAPs contained in the particulates, including but not limited to, antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, mercury, nickel, and selenium.
"Pollution prevention" means source reduction as defined under the Pollution Prevention Act of 1990 (e.g., equipment or technology modifications, process or procedure modifications, reformulation or redesign of products, substitution of raw materials, and improvements in housekeeping, maintenance, training, or inventory control), and other practices that reduce or eliminate the creation of pollutants through increased efficiency in the use of raw materials, energy, water, or other resources, or protection of natural resources by conservation.
"Reactive fluxing" means the use of any gas, liquid, or solid flux (other than cover flux) that results in a HAP emission. Argon and nitrogen are not reactive and do not produce HAP.
"Reconstruction" means the replacement of components of an affected source or emission unit such that the fixed capital cost of the new components exceeds 50% of the fixed capital cost that would be required to construct a comparable new affected source, and it is technologically and economically feasible for the reconstructed source to meet relevant standard or standards established in 12.0 of this regulation. Replacement of the refractory in a furnace is routine maintenance and is not a reconstruction. The repair and replacement of in-line fluxer components (e.g., rotors/shafts, burner tubes, refractory, warped steel) is considered to be routine maintenance and is not considered a reconstruction. In-line fluxers are typically removed to a maintenance/repair area and are replaced with repaired units. The replacement of an existing in-line fluxer with a repaired unit is not considered a reconstruction.
"Residence time" means, for an afterburner, the duration of time required for gases to pass through the afterburner combustion zone. Residence time is calculated by dividing the afterburner combustion zone volume in cubic feet by the volumetric flow rate of the gas stream in actual cubic feet per second.
"Rotary dross cooler" means a water-cooled rotary barrel device that accelerates cooling of dross.
"Runaround scrap" means scrap materials generated on-site by aluminum casting, extruding, rolling, scalping, forging, forming/stamping, cutting, and trimming operations and that do not contain paint or solid coatings. Uncoated/unpainted aluminum chips generated by turning, boring, milling, and similar machining operations may be clean charge if they have been thermally dried or treated by a centrifugal cleaner, but are not considered to be runaround scrap.
"Scrap dryer/delacquering kiln/decoating kiln" means a unit used primarily to remove various organic contaminants such as oil, paint, lacquer, ink, plastic, or rubber from aluminum scrap (including used beverage containers) prior to melting.
"Secondary aluminum processing unit" or "SAPU". An existing SAPU means all existing group 1 furnaces and all existing in-line fluxers within a secondary aluminum production facility. Each existing group 1 furnace or existing in-line fluxer is considered an emission unit within a secondary aluminum processing unit. A new SAPU means any combination of individual group 1 furnaces and in-line fluxers within a secondary aluminum processing facility which either were constructed or reconstructed after February 11, 1999, or have been permanently redesignated as new emission units pursuant to 12.6.11.6 of this regulation. Each of the group 1 furnaces or in-line fluxers within a new SAPU is considered an emission unit within that secondary aluminum processing unit.
"Secondary aluminum production facility" means any establishment using clean charge, aluminum scrap, or dross from aluminum production, as the raw material and performing one or more of the following processes: scrap shredding, scrap drying/delacquering/decoating, thermal chip drying, furnace operations (i.e., melting, holding, sweating, refining, fluxing, or alloying), recovery of aluminum from dross, inline fluxing, or dross cooling. A secondary aluminum production facility may be independent or part of a primary aluminum production facility. For purposes of 12.0 of this regulation, aluminum die casting facilities, aluminum foundries, and aluminum extrusion facilities are not considered to be secondary aluminum production facilities if the only materials they melt are clean charge, customer returns, or internal scrap, and if they do not operate sweat furnaces, thermal chip dryers, or scrap dryers/delacquering kilns/decoating kilns. The determination of whether a facility is a secondary aluminum production facility is only for purposes of 12.0 of this regulation and any regulatory requirements which are derived from the applicability of 12.0 of this regulation, and is separate from any determination which may be made under other environmental laws and regulations, including whether the same facility is a "secondary metal production facility" as that term is used in the Act and in 3.1 of 7 DE Admin. Code 1125 of State of Delaware "Regulations Governing the Control of Air Pollution".
"Sidewell" means an open well adjacent to the hearth of a furnace with connecting arches between the hearth and the open well through which molten aluminum is circulated between the hearth, where heat is applied by burners, and the open well, which is used for charging scrap and solid flux or salt to the furnace, injecting fluxing agents, and skimming dross.
"Sweat furnace" means a furnace used exclusively to reclaim aluminum from scrap that contains substantial quantities of metal by using heat to separate the low-melting point aluminum from the scrap while the higher melting-point metal remains in solid form. These units are also commonly known as dry hearth furnaces.
"TEQ" means the international method of expressing toxicity equivalents for dioxins and furans as defined in "Interim Procedures for Estimating Risks Associated with Exposures to Mixtures of Chlorinated Dibenzo-p-Dioxins and -Dibenzofurans (CDDs and CDFs) and 1989 Update" (EPA-625/3-89/016).
"THC" means, for the purposes of 12.0 of this regulation, total hydrocarbon emissions that also serve as a surrogate for the emissions of organic HAP compounds.
"Thermal chip dryer" means a device that uses heat to evaporate oil or oil/water mixtures from unpainted/uncoated aluminum chips. Pre-heating boxes or other dryers which are used solely to remove water from aluminum scrap are not considered to be thermal chip dryers for purposes of 12.0 of this regulation.
"Three-day, 24-hour rolling average" means daily calculations of the average 24-hour emission rate (lbs/ton of feed/charge), over the three most recent consecutive 24-hour periods, for a secondary aluminum processing unit.
"Total reactive chlorine flux injection rate" means the sum of the total weight of chlorine in the gaseous or liquid reactive flux and the total weight of chlorine in the solid reactive chloride flux, divided by the total weight of feed/charge, as determined by the procedure in 12.13.15 of this regulation.
Click here to view Image (12-1)
where,
LtiPM = The PM emission limit for individual emission unit i in 12.6.9.1 and 12.6.9.2 of this regulation for a group 1 furnace or in 12.6.10.2 of this regulation for an in-line fluxer;
Tti = The feed/charge rate, for an operating cycle, for individual emission unit i;
LcPM = The PM emission limit for the secondary aluminum processing unit; and
n = The total number of emission units.
Note: In-line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the PM limit.
Click here to view Image (12-2)
where,
LtiHCl = The HCl emission limit for individual emission unit i in 12.6.9.4 of this regulation for a group 1 furnace or in 12.6.10.1 of this regulation for an in-line fluxer;
Tti = The feed/charge rate, for an operating cycle, for individual emission unit i;
LcHCl = The HCl emission limit for the secondary aluminum processing unit; and
n = The total number of emission units.
Note: In-line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the HCl limit.
Click here to view Image (12-3)
where,
LtiD/F= The D/F emission limit for individual emission unit i in 12.6.9.3 of this regulation for a group 1 furnace;
Tti = The feed/charge rate, for an operating cycle, for individual emission unit i;
LcD/F= The D/F emission limit for the secondary aluminum processing unit; and
n = The total number of emission units.
Note: Clean charge furnaces cannot be included in this calculation since they are not subject to the D/F limit.
Click here to view Image (12-4)
where,
Eday = The daily PM, HCl, or D/F emission rate for the secondary aluminum processing unit for the 24-hour period;
Ti = The total amount of feed, or aluminum produced, for emission unit i for the 24-hour period (tons or Mg);
ERi = The measured emission rate for emission unit i as determined in the performance test (lb/ton or g/Mg of feed/charge); and
n = The number of emission units in the secondary aluminum processing unit.
Wt = F1* W1 + F2 * W2(12-5)
where,
Wt = Total chlorine usage, by weight;
F1 = Fraction of gaseous or liquid flux that is chlorine;
W1 = Weight of reactive flux gas or liquid injected;
F2 = Fraction of solid reactive chloride flux that is chlorine (e.g., F = 0.75 for magnesium chloride); and
W2 = Weight of solid reactive flux;
E = (C * MW * Q * K1 * K2) / (MV * P * 106) (12-6)
where,
E = Emission rate of measured pollutant, kg/Mg (lb/ton) of feed;
C = Measured volume fraction of pollutant, ppmv;
MW = Molecular weight of measured pollutant, g/g-mole (lb/lb-mole): THC (as propane) = 44.11;
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr);
K1 = Conversion factor, 1 kg/1,000 g (1 lb/lb);
K2 = Conversion factor, 1,000 L/m3 (1 ft3/ft3);
MV = Molar volume, 24.45 L/g-mole (385.3 ft3/lb-mole); and
P = Production rate, Mg/hr (ton/hr).
E = (C * Q * K1) / P (12-7)
where,
E = Emission rate of PM or HCl, kg/Mg (lb/ton) of feed;
C = Concentration of PM or HCl, g/dscm (gr/dscf);
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr);
K1 = Conversion factor, 1 kg/1,000 g (1 lb/7,000 gr); and
P = Production rate, Mg/hr (ton/hr).
E = (C * Q) / P (12-8)
where,
E = Emission rate of D/F, g/Mg (gr/ton) of feed;
C = Concentration of D/F, g /dscm (gr/dscf);
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr); and
P = Production rate, Mg/hr (ton/hr).
%R = [(Li - Lo) / (Li)] * 100 (12-9)
where,
%R = Percent reduction of the control device;
Li = Inlet loading of pollutant, kg/Mg (lb/ton); and
Lo = Outlet loading of pollutant, kg/Mg (lb/ton).
Click here to view Image (12-10)
where,
EcPM = The mass-weighted PM emissions for the secondary aluminum processing unit;
EtiPM = Measured PM emissions for individual emission unit i;
Tti = The average feed rate for individual emission unit i during the operating cycle or performance test period; and
n = The number of emission units in the secondary aluminum processing unit.
Click here to view Image (12-11)
where,
EcHCl = The mass-weighted HCl emissions for the secondary aluminum processing unit;
EtiHCl = Measured HCl emissions for individual emission unit i;
Tti = The average feed rate for individual emission unit i during the operating cycle or performance test period; and
n = The number of emission units in the secondary aluminum processing unit.
Click here to view Image (12-12)
where,
EcD/F = The mass-weighted D/F emissions for the secondary aluminum processing unit;
EtiD/F = Measured D/F emissions for individual emission unit i;
Tti = The average feed rate for individual emission unit i during the operating cycle or performance test period; and
n = The number of emission units in the secondary aluminum processing unit.
Owners or operators of affected sources subject to the provisions of 12.0 of this regulation must also comply with the requirements in 4.0 of this regulation, according to the applicability of 4.0 of this regulation to such sources as identified in Table 12-1 of this regulation.
Table 12-1 - Applicability of 3.0 to 12.0 of This Regulation
| General Provisions References | Applies to 12.0 | Comment |
| 3.1.1.1 - 3.1.1.4 | Yes | |
| 3.1.1.5 | No | |
| 3.1.1.6 | Yes | |
| 3.1.1.7 - 3.1.1.9 | No | |
| 3.1.1.10 - 3.1.1.14 | Yes | |
| 3.1.2.1 | Yes | EPA retains approval authority. |
| 3.1.2.2 | No | |
| 3.1.2.3 | Yes | |
| 3.1.3.1 | Yes | |
| 3.1.3.2 | Yes | 12.1.5 exempts area sources subject to this section from the obligation to obtain a Title V operating permit. |
| 3.1.3.3 - 3.1.3.4 | No | |
| 3.1.3.5 | Yes | |
| 3.1.4 | No | |
| 3.1.5 | Yes | |
| 3.2 | Yes | Additional definitions in 12.4. |
| 3.3 | Yes | |
| 3.4.1.1 - 3.4.1.2 | Yes | |
| 3.4.1.3 - 3.4.1.5 | No | |
| 3.4.2 - 3.4.3 | Yes | |
| 3.5.1 | Yes | |
| 3.5.2.1 | Yes | |
| 3.5.2.2 | No | |
| 3.5.2.3 - 3.5.2.4 | Yes | |
| 3.5.2.5 | No | |
| 3.5.2.6 | Yes | |
| 3.5.3 | No | |
| 3.5.4 - 3.5.4.1.2.6 | Yes | |
| 3.5.4.1.2.7 | No | |
| 3.5.4.1.2.8 | Yes | |
| 3.5.4.1.2.9 | No | |
| 3.5.4.1.2.10 | Yes | |
| 3.6.1 | Yes | |
| 3.6.2.1 - 3.6.2.5 | Yes | |
| 3.6.2.6 | No | |
| 3.6.2.7 | Yes | |
| 3.6.3.1 | Yes | 12.2 specifies dates. |
| 3.6.3.2 | Yes | |
| 3.6.3.3 - 3.6.3.5 | No | |
| 3.6.3.5 | Yes | |
| 3.6.4 | No | |
| 3.6.5.1 | Yes | 12.11 requires plan. |
| 3.6.5.2 | No | |
| 3.6.5.3 - 3.6.5.3.1 | Yes | |
| 3.6(e)(3)(ii) | No | |
| 3.6.5.3.2 - 3.6.5.3.9 | Yes | |
| 3.6.6 | Yes | |
| 3.6.7 | No | |
| 3.6.8 - 3.6.8.2.1 | Yes | |
| 3.6.8.2.2 | No | |
| 3.6.8.2.3 | Yes | |
| 3.6.8.3 | No | |
| 3.6.8.4 - 3.6.8.5.3 | Yes | |
| 3.6.8.5.4 | No | |
| 3.6.8.5.5 - 3.6.8.9 | Yes | |
| 3.6.9.1 - 3.6.9.14 | Yes | |
| 3.6.9.15 | No | |
| 3.6.9.16 | Yes | |
| 3.6.10 | Yes | |
| 3.7.1 - 3.7.1.2 | Yes | Except 12.12 establishes dates for initial performance tests. |
| 3.7.1.2.1 - 3.7.1.2.7 | No | |
| 3.7.1.2.8 - 3.7.1.3 | Yes | |
| 3.7.2 | Yes | |
| 3.7.3 | Yes | |
| 3.7.4 | Yes | |
| 3.7.5 | Yes | |
| 3.7.6 | Yes | |
| 3.7.7 - 3.7.7.1 | Yes | |
| 3.7.7.2 | No | |
| 3.7.7.3 | Yes | |
| 3.7.8 | Yes | |
| 3.8.1.1 | Yes | |
| 3.8.1.2 | Yes | |
| 3.8.1.3 | No | |
| 3.8.1.4 | Yes | |
| 3.8.2 | Yes | |
| 3.8.3.1 - 3.8.3.3 | Yes | |
| 3.8.3.4 - 3.8.3.8 | Yes | |
| 3.8.4 | Yes | |
| 3.8.5 | Yes | |
| 3.8.6.1 - 3.8.6.5 | No | 12.11.23 includes provisions for monitoring alternatives. |
| 3.8.6.6 | Yes | |
| 3.8.7.1 | Yes | |
| 3.8.7.2 | No | 12.13 requires five six-minute averages for an aluminum scrap shredder. |
| 3.8.7.3 - 3.8.7.5 | Yes | |
| 3.9.1 | Yes | |
| 3.9.2 - 3.9.2.2 | Yes | |
| 3.9.2.3 | No | |
| 3.9.2.4 - 3.9.2.4.1 | Yes | |
| 3.9.2.4.2 - 3.9.2.4.4 | No | |
| 3.9.2.4.5 - 3.9.2.5 | Yes | |
| 3.9.3 | Yes | |
| 3.9.4 | Yes | |
| 3.9.5 | Yes | |
| 3.9.6 | Yes | |
| 3.9.7 | Yes | |
| 3.9.8.1 - 3.9.8.3 | Yes | Except 12.16 establishes dates for notification of compliance status reports. |
| 3.9.8.4 | No | |
| 3.9.8.5 - 3.9.8.6 | Yes | |
| 3.9.9 | Yes | |
| 3.9.10 | Yes | |
| 3.10.1 | Yes | |
| 3.10.2 | Yes | 12.18 includes additional requirements. |
| 3.10.3.1 | Yes | |
| 3.10.3.2 - 3.10.3.4 | No | |
| 3.10.3.5 | Yes | |
| 3.10.3.6 | Yes | |
| 3.10.3.7 - 3.10.3.8 | Yes | |
| 3.10.3.9 | No | |
| 3.10.3.10 - 3.10.3.13 | Yes | |
| 3.10.3.14 | Yes | |
| 3.10.3.15 | Yes | |
| 3.10.4.1 | Yes | |
| 3.10.4.2 | Yes | |
| 3.10.4.3 | Yes | |
| 3.10.4.4 - 3.10.4.5 | Yes | |
| 3.10.5.1 - 3.10.5.2 | Yes | |
| 3.10.5.3 - 3.10.5.3.1.2 | Yes | |
| 3.10.5.3.1.3 | No | |
| 3.10.5.3.1.4 - 3.10.5.3.8 | Yes | Reporting deadline given in 12.17 |
| 3.10.5.4 | Yes | |
| 3.10.6 | Yes | |
| 3.11.1 - 3.11.2 | No | Flares not applicable. |
| 3.11.1 - 3.12.3 | Yes | EPA retains authority for applicability determinations. |
| 3.13 | Yes | |
| 3.14 | Yes | Chapters 3 and 5 of ACGIH Industrial Ventilation Manual for capture/collection systems; and Interim Procedures for Estimating Risk Associated with Exposure to Mixtures of Chlorinated Dibenzofurans (CDDs and CDFs) and 1989 Update (incorporated by reference in 12.3). |
| 3.15 | Yes |
| Table 12-2 Emission Standards for New and Existing Affected Sources | |||
| Affected source/Emission unit | Pollutant | Limit | Units |
| All new and existing affected sources and emission units that are controlled with a PM add-on control device and that choose to monitor with a continuous opacity monitor (COM) and all new and existing aluminum scrap shredders that choose to monitor with a COM or to monitor visible emissions | Opacity | 10 | % |
| New and existing aluminum scrap shredder | PM | 0.01 | gr/dscf |
| New and existing thermal chip dryer | THC D/Fa | 0.80 2.50 | 1b/ton of feed µg TEQ/Mg of feed |
| New and existing scrap/dryer delacquering kiln/decoating kiln | PM HCl THC D/Fa | 0.08 0.80 0.06 0.25 | 1b/ton of feed 1b/ton of feed 1b/ton of feed µg TEQ/Mg of feed |
| Or Alternative limits if afterburner has a design residence time of at least 1 second and operates at a temperature of at least 760 °C (1400 °F) | PM HCl THC D/Fa | 0.30 1.50 0.20 5.0 | 1b/ton of feed 1b/ton of feed 1b/ton of feed µg TEQ/Mg of feed |
| New and existing sweat furnace | D/Fa | 0.80 | ng TEQ/dscm@ 11% O2b |
| New and existing dross-only furnace | PM | 0.30 | 1b/ton of feed |
| New and existing in-line fluxerc | HCl PM | 0.04 0.01 | 1b/ton of feed 1b/ton of feed |
| New and existing in-line fluxer with no reactive fluxing | No Limit | Work practice: no reactive fluxing | |
| New and existing rotary dross cooler | PM | 0.04 | gr/dscf |
| New and existing clean furnace (Group 2) | No Limit | Work practice: clean charge only and no reactive fluxing | |
| New and existing group 1 melting/holding furnace (processing only clean charge)c | PM HCL | 0.80 0.40 or 10 | 1b/ton of feed 1b/ton of feed percent of the HCl upstream of an add-on control device |
| New and existing group 1 furnacec | PM HCL D/Fa | 0.40 0.40 or 10 15.0 | 1b/ton of feed 1b/ton of feed percent of the HCl upstream of an add-on control device µg TEQ/Mg of feed |
| New and existing group 1 furnacec with clean charge only | PM HCL D/Fa | 0.40 0.40 or 10 No Limit | 1b/ton of feed 1b/ton of feed percent of the HCl upstream of an add-on control device Work practice: clean charge only |
| New and existing secondary aluminum processing unita,d (consists of all group 1 furnaces and existing in-line flux boxes at the facility, or all simultaneously constructed new group 1 furnaces and new in-line fluxers | PM e | Click here to view Image | |
| HCl f | Click here to view Image | ||
| D/F g | Click here to view Image | ||
a D/F limit applies to a unit at a major or area source.
b Sweat furnaces equipped with afterburners meeting the specifications in 12.6.6.1 of this regulation are not required to conduct a performance test.
c These limits are also used to calculate the limits applicable to secondary aluminum processing units.
dEquation definitions:
LtiPM = the PM emission limit for individual emission unit i in the secondary aluminum processing unit [kg/Mg (lb/ton) of feed];
Tti = the feed rate for individual emission unit i in the secondary aluminum processing unit [tons of feed per operating cycle];
LcPM = the overall PM emission limit for the secondary aluminum processing unit [kg/Mg (lb/ton) of feed];
LtiHCl = the HCl emission limit for individual emission unit i in the secondary aluminum processing unit [kg/Mg (lb/ton) of feed];
LcHCl = the overall HC1 emission limit for the secondary aluminum processing unit [kg/Mg (lb/ton) of feed];
LtiD/F = the D/F emission limit for individual emission unit i in the secondary aluminum processing unit [µg TEQ/Mg (gr TEQ/ton) of feed];
LcD/F = the overall D/F emission limit for the secondary aluminum processing unit [µg TEQ/Mg (gr TEQ/ton) of feed]; and
n = the number of emission units in the secondary aluminum processing unit.
eIn-line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the PM limit.
fIn-line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the HC1 limit.
gClean charge furnaces cannot be included in this calculation since they are not subject to the D/F limit.
| Table 12-3 Summary Of Operating Requirements For New And Existing Affected Sources And Emission Units | |||
| Affected source/Emission unit | Monitor type/ Operation/Process | Operating requirements | |
| All affected sources and emission units with an add-on air pollution control device | Emission capture and collection system | Design and install in accordance with "Industrial Ventilation: A Handbook of Recommended Practice"; operate in accordance with OM&M plan.b | |
| All affected sources and emission units subject to production-based (lb/ton of feed) emission limits a | Charge/feed weight or Production weight | Operate a device that records the weight of each charge; operate in accordance with OM&M plan.b | |
| Group 1 furnace, group 2 furnace, in-line fluxer, sweat furnace, and scrap dryer/ delacquering kiln/decoating kiln | Labeling | Identification, operating parameter ranges and operating requirements posted at affected sources and emission units; control device temperature and residence time requirements posted at scrap dryer/delacquering kiln/decoating kiln or sweat furnace. | |
| Aluminum scrap shredder with fabric filter | Bag leak detector or | Initiate corrective action within 1-hr of alarm and complete in accordance with OM&M plan b; operate such that alarm does not sound more than 5% of operating time in six-month period. | |
| Continuous opacity monitor (COM) or | Initiate corrective action within 1-hr of a six-minute average opacity reading of 5% or more and complete in accordance with OM&M plan.b | ||
| Visible emissions | Initiate corrective action within 1-hr of any observed visible emissions and complete in accordance with the OM&M plan.b | ||
| Thermal chip dryer with afterburner | Afterburner operating temperature | Maintain average temperature for each three-hr period at or above average operating temperature during the performance test. | |
| Afterburner operation | Operate in accordance with OM&M plan.b | ||
| Feed material | Operate using only unpainted aluminum chips. | ||
| Scrap dryer/delacquering kiln/ decoating kiln with afterburner and lime-injected fabric filter | Afterburner operating temperature | Maintain average temperature for each three-hr period at or above average operating temperature during the performance test. | |
| Afterburner operation | Operate in accordance with OM&M plan.b | ||
| Bag leak detector or | Initiate corrective action within 1-hr of alarm and complete in accordance with the OM&M plan; boperate such that alarm does not sound more than 5% of operating time in six-month period. | ||
| COM | Initiate corrective action within one-hr of a six-minute average opacity reading of 5% or more and complete in accordance with the OM&M plan.b | ||
| Fabric filter inlet temperature | Maintain average fabric filter inlet temperature for each three-hr period at or below average temperature during the performance test plus 14 °C (plus 25 °F). | ||
| Lime injection rate | Maintain free-flowing lime in the feed hopper or silo at all times for continuous injection systems; maintain feeder setting at level established during the performance test for continuous injection systems. | ||
| Sweat furnace with afterburner | Afterburner operating temperature | If a performance test was conducted, maintain average temperature for each three-hr period at or above average operating temperature during the performance test; if a performance test was not conducted and afterburner meets specifications in 12.6.6.1 of this regulation, maintain average temperature for each three-hr period at or above 872 °C (1600 °F). | |
| Afterburner operation | Operate in accordance with OM&M plan.b | ||
| Dross-only furnace with fabric filter | Bag leak detector or | Initiate corrective action within one-hr of alarm and complete in accordance with the OM&M plan; boperate such that alarm does not sound more than 5% of operating time in six-month period. | |
| COM | Initiate corrective action within 1-hr of a six-minute average opacity reading of 5% or more and complete in accordance with the OM&M plan.b | ||
| Feed/charge material | Operate using only dross and salt flux as the feed/charge material. | ||
| Rotary dross cooler with fabric filter | Bag leak detector or | Initiate corrective action within 1-hr of alarm and complete in accordance with the OM&M plan; boperate such that alarm does not sound more than 5% of operating time in six-month period. | |
| COM | Initiate corrective action within 1-hr of a six-minute average opacity reading of 5% or more and complete in accordance with the OM&M plan.b | ||
| In-line fluxer with lime-injected fabric filter (including those that are part of a secondary aluminum processing unit) | Bag leak detector or | Initiate corrective action within one-hr of alarm and complete in accordance with the OM&M plan; boperate such that alarm does not sound more than 5% of operating time in six-month period. | |
| COM | Initiate corrective action within 1-hr of a six-minute average opacity reading of 5% or more and complete in accordance with the OM&M plan.b | ||
| Lime injection rate | Maintain free-flowing lime in the feed hopper or silo at all times for continuous injection systems; maintain feeder setting at level established during the performance test for continuous injection systems. | ||
| Reactive flux injection rate | Maintain reactive flux injection rate at or below rate used during the performance test for each operating cycle or time period used in the performance test. | ||
| In-line fluxer (using no reactive flux materials | Flux materials | Use no reactive flux. | |
| Group 1 furnace with lime-injected fabric filter (including those that are part of a secondary aluminum processing unit) | Bag leak detector or | Initiate corrective action within 1-hr of alarm and complete in accordance with the OM&M plan; b operate such that alarm does not sound more than 5% of operating time in six-month period. | |
| COM | Initiate corrective action within one-hr of a six-minute average opacity reading of 5% or more and complete in accordance with the OM&M plan.b | ||
| Fabric filter inlet temperature | Maintain average fabric filter inlet temperature for each 3-hr period at or below average temperature during the performance test plus 14 °C (plus 25 °F). | ||
| Reactive flux injection rate | Maintain reactive flux injection rate (kg/Mg or lb/hr) at or below rate used during the performance test for each operating cycle or time period used in the performance test. | ||
| Lime injection rate | Maintain free-flowing lime in the feed hopper or silo at all times for continuous injection systems; maintain feeder setting at level established during the performance test for continuous injection systems. | ||
| Maintain molten aluminum level | Operate sidewell furnaces such that the level of molten metal is above the top of the passage between sidewell and hearth during reactive flux injection, unless the hearth is also controlled. | ||
| Fluxing in sidewell furnace hearth | Add reactive flux only to the sidewell of the furnace unless the hearth is also controlled. | ||
| Group 1 furnace without add-on controls (including those that are part of a secondary aluminum processing unit) | Reactive flux injection rate | Maintain reactive flux injection rate (kg/Mg or lb/hr) at or below rate used during the performance test for each operating cycle or time period used in the performance test. | |
| Site-specific monitoring plan c | Operate furnace within the range of charge materials, contaminant levels, and parameter values established in the site-specific monitoring plan. | ||
| Feed material (melting/holding furnace) | Use only clean charge. | ||
| Clean (group 2) furnace | Charge and flux materials | Use only clean charge. Use no reactive flux. | |
aThermal chip dryers, scrap dryers/delacquering kilns/decoating kilns, dross-only furnaces, in-line fluxers and group 1 furnaces including melting/holding furnaces.
bOM&M plan-Operation, maintenance, and monitoring plan.
cSite-specific monitoring plan. Owner/operators of group 1 furnaces without control devices must include a section in their OM&M plan that documents work practice and pollution prevention measures, including procedures for scrap inspection, by which compliance is achieved with emission limits and process or feed parameter-based operating requirements. This plan and the testing to demonstrate adequacy of the monitoring plan must be developed in coordination with and approved by the Department.
| Table 12-4 Summary Of Monitoring Requirements For New And Existing Affected Sources And Emission Units | ||
| Affected source/Emission unit | Monitor type/ Operation/ Process | Monitoring requirements |
| All affected sources and emission units with an add-on air pollution control device | Emission capture and collection system | Annual inspection of all emission capture, collection, and transport systems to ensure that systems continue to operate in accordance with ACGIH standards. |
| All affected sources and emission units subject to production-based (lb/ton of feed/charge) emission limitsa | Feed/charge weight | Record weight of each feed/charge, weight measurement device or other procedure accuracy of ±1% b; calibrate according to manufacturer's specifications, or at least once every six months. |
| Group 1 furnace, group 2 furnace, in-line fluxer, sweat furnace, and scrap dryer/ delacquering kiln/decoating kiln | Labeling | Check monthly to confirm that labels are intact and legible. |
| Aluminum scrap shredder with fabric filter | Bag leak detector or | Install and operate in accordance with "Fabric Filter Bag Leak Detection Guidance" c; record voltage output from bag leak detector. |
| Continuous opacity monitor (COM) or | Design and install in accordance with PS-1; collect data in accordance with 3.0 of this regulation; determine and record six-minute block averages. | |
| Visible emissions | Conduct and record results of 30-minute daily test in accordance with Method 9. | |
| Thermal chip dryer with afterburner | Afterburner operating temperature | Continuous measurement device to meet specifications in 12.11.7.1 of this regulation; record temperature in 15-minute block averages; determine and record three-hr block averages. |
| Afterburner operation | Annual inspection of afterburner internal parts; complete repairs in accordance with the OM&M plan. | |
| Feed/charge material | Record identity of each feed/charge; certify feed/charge materials every six months. | |
| Scrap dryer/delacquering kiln/ decoating kiln with afterburner and lime injected fabric filter | Afterburner operating temperature | Continuous measurement device to meet specifications in 12.7.1 of this regulation; record temperature in 15-minute block averages; determine and record three-hr block averages. |
| Afterburner operation | Annual inspection of afterburner internal parts; complete repairs in accordance with the OM&M plan. | |
| Bag leak detector or | Install and operate in accordance with "Fabric Filter Bag Leak Detection Guidance" c; record voltage output from bag leak detector. | |
| COM | Design and install in accordance with PS-1; collect data in accordance with 3.0 of this regulation; determine and record six-minute block averages. | |
| Lime injection rate | For continuous injection systems, record feeder setting daily and inspect each feed hopper or silo every eight hrs to verify that lime is free-flowing; record results of each inspection. If blockage occurs, inspect every four hrs for three days; return to eight-hr inspections if corrective action results in no further blockage during three-day period. | |
| Fabric filter inlet temperature | Continuous measurement device to meet specifications in 12.11.8.2 of this regulation; record temperatures in 15-minute block averages; determine and record three-hr block averages. | |
| Sweat furnace with afterburner | Afterburner operating temperature | Continuous measurement device to meet specifications in 12.11.7.1 of this regulation; record temperature in 15-minute block averages; determine and record three-hr block averages. |
| Afterburner operation | Annual inspection of afterburner internal parts; complete repairs in accordance with the OM&M plan. | |
| Dross-only furnace with fabric filter | Bag leak detector or | Install and operate in accordance with "Fabric Filter Bag Leak Detection Guidance" c; record voltage output from bag leak detector. |
| COM | Design and install in accordance with PS-1; collect data in accordance with 3.0 of this regulation; determine and record six-minute block averages. | |
| Feed/charge material | Record identity of each feed/charge; certify feed/charge materials every six months. | |
| Rotary dross cooler with fabric filter | Bag leak detector or | Install and operate in accordance with "Fabric Filter Bag Leak Detection Guidance" c; record voltage output from bag leak detector. |
| COM | Design and install in accordance with PS-1; collect data in accordance with 3.0 of this regulation; determine and record six-minute block averages. | |
| In-line fluxer using no reactive flux | Flux materials | Record flux materials; certify every six months for no reactive flux. |
| In-line fluxer with lime-injected fabric filter | Bag leak detector or | Install and operate in accordance with "Fabric Filter Bag Leak Detection Guidance" c; record voltage output from bag leak detector. |
| COM | Design and install in accordance with PS-1; collect data in accordance with 4.0 of this regulation; determine and record six-minute block averages. | |
| Reactive flux injection rate | Weight measurement device accuracy of ±1% b; calibrate according to manufacturer's specifications or at least once every six months; record time, weight and type of reactive flux added or injected for each 15-minute block period while reactive fluxing occurs; calculate and record total reactive flux injection rate for each operating cycle or time period used in performance test; or alternative flux injection rate determination procedure in 12.11.10.5 of this regulation. | |
| Lime injection rate | For continuous injection systems, record feeder setting daily and inspect each feed hopper or silo every eight hrs to verify that lime is free-flowing; record results of each inspection. If blockage occurs, inspect every 4 hrs for three days; return to eight-hr inspections if corrective action results in no further blockage during three-day period. | |
| Group 1 furnace with lime-injected fabric filter | Bag leak detector or | Install and operate in accordance with "Fabric Filter Bag Leak Detection Guidance" c; record voltage output from bag leak detector. |
| COM | Design and install in accordance with PS-1; collect data in accordance with 4.0 of this regulation; determine and record six-minute block averages. | |
| Lime injection rate | For continuous injection systems, record feeder setting daily and inspect each feed hopper or silo every eight hrs to verify that lime is free-flowing; record results of each inspection. If blockage occurs, inspect every four hrs for three days; return to 8-hr inspections if corrective action results in no further blockage during three-day period. | |
| Reactive flux injection rate | Weight measurement device accuracy of ±1% b; calibrate every three months; record time, weight and type of reactive flux added or injected for each 15-minute block period while reactive fluxing occurs; calculate and record total reactive flux injection rate for each operating cycle or time period used in performance test; or alternative flux injection rate determination procedure in 12.11.10.5 of this regulation. | |
| Fabric filter inlet temperature | Continuous measurement device to meet specifications in 12.11.8.2 of this regulation; record temperatures in 15-minute block averages; determine and record three-hr block averages. | |
| Maintain molten aluminum level in sidewell furnace | Maintain aluminum level operating log; certify every six months. | |
| Group 1 furnace without add-on controls | Fluxing in sidewell furnace hearth | Maintain flux addition operating log; certify every six months. |
| Reactive flux injection rate | Weight measurement device accuracy of ±1% b; calibrate according to manufacturer's specifications or at least once every six months; record time, weight and type of reactive flux added or injected for each 15-minute block period while reactive fluxing occurs; calculate and record total reactive flux injection rate for each operating cycle or time period used in performance test; or alternative flux injection rate determination procedure in 12.11.10.5 of this regulation. | |
| OM&M plan (approved by Department) | Demonstration of site-specific monitoring procedures to provide data and show correlation of emissions across the range of charge and flux materials and furnace operating parameters. | |
| Feed material (melting/holding furnace) | Record type of permissible feed/charge material; certify feed/charge materials every six months. | |
| Clean (group 2) furnace | Charge and flux materials | Record charge and flux materials; certify every six months for clean charge and no reactive flux. |
| aThermal chip dryers, scrap dryers/delacquering kilns/decoating kilns, dross-only furnaces, in-line fluxers and group 1 furnaces or melting/holding furnaces. |
| bDepartment may approve measurement devices of alternative accuracy, for example in cases where flux rates are very low and costs of meters of specified accuracy are prohibitive; or where feed/charge weighing devices of specified accuracy are not practicable due to equipment layout or charging practices. |
| cNon-triboelectric bag leak detectors must be installed and operated in accordance with manufacturers' specifications. |
| dDepartment may approve other alternatives including load cells for lime hopper weight, sensors for carrier gas pressure, or HCl monitoring devices at fabric filter outlet. |
7 Del. Admin. Code § 1138-12.0
19 DE Reg. 311 (10/1/2015) (Final)